DPS Sport Ball

ABSTRACT

A DPS (dual pressure system) sport ball incorporating a special, environment friendly casing that forms an exterior surface of the ball, which is bonded to a multiple lining layers to form a laminated sheet. The laminated sheet is sized, printed, and cut out into specifically designed panels using highly optimized and automated specifically developed machines. The panel cut outs are stitched together using a special stitching machine and a specific, compatible bladder is incorporated in the ball. The partially machine stitched ball is then finally closed by manual stitching and the seams are protected with a special adhesive. Resultantly, due to unique construction materials, their unique arrangement, innovative technology, and highly automated manufacturing processes, the DPS sport ball has advantageous durability, playability, controllability and excellent flight characteristics. The DPS sport ball qualifies under the international standards of match/professional balls at a very competitive price.

CROSS-REFERENCE TO RELATED APPLICATIONS

This application claims the benefit of Pakistan Patent Application No.237/2016, filed 22 Apr. 2016, which is hereby incorporated herein byreference in its entirety.

BACKGROUND OF THE INVENTION 1. Field of the Invention

The present invention relates to the materials utilized in theconstruction and method of manufacturing of a sport ball.

2. Description of Related Art

Conventionally, a variety of techniques are utilized in manufacturing asport ball, such as hand-stitching, thermo-bonding, and machinestitching. The hand-stitching technique is comparatively extensive andrequires a highly skilled labor force and prolonged manufacturingprocesses. Consequently, the hand-stitched ball is not cost efficient.

Thermo-bonded sport balls are manufactured within a relatively shorttime span by using machines, but as it is generally seamless, use ofsuch a ball presents many disadvantages including loss of trajectorycontrol over flight during play. Thus, the thermo-bonded ball could notgain popularity and fondness from many international professionalplayers.

Machine-stitched balls are known for their cheap construction, machinestitching and low price. They have become successful in the market, andhave gained popularity among the beginners and general public. Yet dueto poor construction materials and consequently poor durability, themachine stitched ball cannot achieve the international standards ofmatch/professional balls.

The present invention overcomes the many disadvantages present in theconventional ball technologies by utilizing distinctive constructionmaterials, their specific arrangement within the layers, innovativetechniques and highly optimized, automated machines for manufacturingthe sport ball.

BRIEF SUMMARY OF THE INVENTION

The present invention relates to a DPS (dual pressure system) sport ballhaving distinctive construction material, their novel and specificarrangements, innovative techniques and method of manufacturing thesame. The DPS sport ball incorporates two major constructioncomponents—a plurality of panels and a bladder, wherein the panelsinclude specifically developed outer casing material bonded to multiplelining layers.

The bladder incorporated herein is a specially developed rubber bladder,which can additionally be thread wound or fabric wrapped to maintainrobustness, round shape, and air retention within the ball.

During the manufacturing, the present invention utilizes highlyautomated and optimized machines for sheet laminating, sheet sizing,printing of panels, their debossing, cutting, die-punching, machinestitching, and their manual stitching, seam protection so that the ballmanufactured is not only robust and round, but also has increaseddurability, quality, playability, controllability and has an excellentflight characteristics.

In an exemplary embodiment, the present invention is a DPS sport ballcomprising a casing material that forms an exterior surface of the ball,a multiple lining system bonded with the casing material to form panelsusing highly efficient automated manufacturing processes, and acompatible bladder to maintain shape of the ball, wherein the panels area majority stitched together on a highly optimized stitching machine andthen manually stitched to finalize the product.

The casing material can be selected from the group consisting ofenvironment friendly polyurethane (EPU), normal PU, water-borne PUdispersion (WPU), PU micro-fiber, PU high solid, and TPU (thermoplasticpolyurethane).

The multiple lining system can comprise five lining layers.

The multiple lining system can comprise lining layers of foam and fabricwith a specific arrangement, wherein foam and the fabric are bondedusing a water-based natural adhesive.

A first lining layer can be a fabric selected from the group consistingof woven and non-woven fabric bonded to the casing material of the sportball.

A second lining layer can be a compatible foam, wherein the foam isbonded to the first lining layer. The compatible foam can be athermoplastic elastomer (TPE) foam.

A third lining layer can be a fabric selected from group consisting ofpolyester viscose, polyester cotton, and 100% polyester fabric, whereinthe third lining layer is bonded to the second lining layer.

A fourth lining layer can be a compatible foam, wherein the fourthlining layer is bonded to the third lining layer. The compatible foamcan be TPE foam. The dimension of the fourth lining layer can be lessthan the preceding layers.

A fifth lining layer can be a compatible foam, wherein the fifth lininglayer is bonded to the fourth lining layer. The compatible foam can beTPE foam. The fifth lining layer can be lesser or equal in size of thebonded fourth layer. The fifth lining layer can be in the form of one ormore patches. The shape of the fifth lining layer can be similar ordifferent from the preceding layers. The fifth lining layer can be roundin shape. The fifth lining layer can have a diameter in the range from3.5 cm-5 cm. The fifth lining layer can contain one or more holes wherein case of more, holes are different or similar in diameter or shapefrom one another. The fifth lining layer can contain a hole in thecenter of one or more patches. The diameter of the hole can be in therange from 0.7-2 cm.

All the lining layers can be bonded by a natural or synthetic adhesive.All the lining layers can be bonded by a water-based natural adhesive.

Each panel of the DPS can include an outer casing material and fivelining layers. Each panel can have a particular shape and size. Thepanels can incorporate a shape selected from the group consisting ofoctagonal, hexagonal, pentagonal, circular, and other specific shapes.

The DPS can comprise a number of panels, for example, 6, 10, 12, 14, 20,32, 36 panels.

The panels can be debossed with two parallel lines.

The panels can be at least partially stitched by a highly optimizedstitching machine. The stitching machine can be equipped with an airpressure system.

The partially machine stitched ball is inverted inside-out so as tocontain a specially developed rubber bladder in it.

The bladder can be selected from the group consisting of naturallatex/rubber, synthetic latex/rubber including carbon-latex, butyl, andPU.

The bladder can additionally be wrapped with a fabric around it. Thebladder can be a thread wound bladder.

Portions of panels within the ball, not stitched by a stitching machine,can be manually stitched to close the ball.

A special adhesive can be used to protect the seam gaps.

A ball that absorbs too much water will not roll very far if at all, andplayers will definitely notice it when they head the ball. The ball muststay afloat as much as possible and not sink like a stone. Under extremeconditions, when it has rained for hours and the ground is soaked, anyball will absorb some water. Thus, how much it absorbs is crucial.

In various embodiments, the water uptake by the present ball can be lessthan 0.4%.

A method of manufacturing a DPS sport ball can comprise sheetlamination, sheet sizing, printing of the panels, their debossing,cutting, die-punching, machine stitching, manual stitching and seamprotection.

The sheet sizing can be done in accordance with the specificrequirements of the shape and/or number of the panels by a highlyspecific laser guided presses.

The panels can be printed on the sheet by a highly optimizedauto-printing machine.

A plurality of the panels can have a specific shape or size and printedin a single stroke. The printed panels can be debossed by a debossingmachine. The printed panels can be debossed with two parallel lines.

A plurality of the panels can be cut out in a specific shape and size bya specifically developed cutting machine in a single stroke.

The multi-layered panels can be punched by computer numeric controlled(CNC) punching presses to form holes on both sides of the panels in onestroke in order to facilitate the manual stitching. The panels can bestitched together by a stitching machine. The stitching machine cancontain a special air pressure system to press and control the panelwhile stitching. The machine-stitched panels can have a bonded bladderthat is manually reversed.

The fourth and fifth lining layers can be bonded to the succeedinglayers with a water-based natural adhesive so that each panel cancomprise an outer casing material and five lining layers.

The ball is inverted manually and the bladder is incorporated in thepartially machine stitched ball.

Remaining portions of the ball are manually stitched to close the ball.

The seam gap can be protected by a special adhesive manually applied orapplied by auto-machine.

The ball can be optionally passed through a molding process to retainround shape of a ball.

These and other objects, features and advantages of the presentinvention will become more apparent upon reading the followingspecification in conjunction with the accompanying drawing figures.

BRIEF DESCRIPTION OF THE DRAWINGS

FIG. 1 illustrates the cross-section of the layers within a sheet.

FIG. 2 illustrates a closer view of the panel with the additional foamlayers (i.e. the fourth foam layer and fifth, round patch, layer)attached.

FIG. 3 illustrates an average sized sheet.

FIG. 4a illustrates printing of average 24 specifically designed panelson a sheet in one stroke.

FIG. 4b illustrates printing of average 42 circular panels on a sheet,in one stroke.

FIG. 4c illustrates printing of average 42 hexagonal panels on a sheet,in one stroke.

FIG. 4d illustrates printing of average 104 pentagonal panels on asheet, in one stroke.

FIG. 4e illustrates printing of 36 pentagonal panels on a sheet, in onestroke.

FIG. 5 illustrates debossing of panels on a printed sheet, in onestroke.

FIG. 6a illustrates cutting of panels on a sheet, in one stroke.

FIG. 6b illustrates cutting of average 98 hexagonal panels on a sheet,in one stroke.

FIG. 7a illustrates an outer view of the preferable panel having adebossing effect.

FIG. 7b illustrates an inner view of the preferable panel havingadditional foam layers attached.

FIG. 7c illustrates exemplary different shapes panel cut-outs.

FIG. 7d illustrates exemplary different shapes panel cut-outs with roundpatch layer.

FIG. 8 illustrates a die-punching machine.

FIG. 9 illustrates a specifically developed stitching machine.

FIG. 10 illustrates an overall panel's appearance when they have beenmachine stitched, and the additional foam layers have been attached.

FIG. 11a illustrates an exemplary fabric wrapped bladder.

FIG. 11b illustrates an exemplary thread wound bladder.

FIG. 12a illustrates an exemplary DPS sport ball with exposed bladderbefore manual stitching.

FIG. 12b illustrates an overall appearance of an exemplary DPS sportball after manual stitching.

FIG. 13 illustrates application of special adhesive to protect the seamgaps.

DETAIL DESCRIPTION OF THE INVENTION

To facilitate an understanding of the principles and features of thevarious embodiments of the invention, various illustrative embodimentsare explained below. Although exemplary embodiments of the invention areexplained in detail, it is to be understood that other embodiments arecontemplated. Accordingly, it is not intended that the invention islimited in its scope to the details of construction and arrangement ofcomponents set forth in the following description or illustrated in thedrawings. The invention is capable of other embodiments and of beingpracticed or carried out in various ways. Also, in describing theexemplary embodiments, specific terminology will be resorted to for thesake of clarity.

It must also be noted that, as used in the specification and theappended claims, the singular forms “a,” “an” and “the” include pluralreferences unless the context clearly dictates otherwise. For example,reference to a component is intended also to include composition of aplurality of components. References to a composition containing “a”constituent is intended to include other constituents in addition to theone named.

Also, in describing the exemplary embodiments, terminology will beresorted to for the sake of clarity. It is intended that each termcontemplates its broadest meaning as understood by those skilled in theart and includes all technical equivalents which operate in a similarmanner to accomplish a similar purpose.

Ranges may be expressed herein as from “about” or “approximately” or“substantially” one particular value and/or to “about” or“approximately” or “substantially” another particular value. When such arange is expressed, other exemplary embodiments include from the oneparticular value and/or to the other particular value.

Similarly, as used herein, “substantially free” of something, or“substantially pure”, and like characterizations, can include both being“at least substantially free” of something, or “at least substantiallypure”, and being “completely free” of something, or “completely pure”.

By “comprising” or “containing” or “including” is meant that at leastthe named compound, element, particle, or method step is present in thecomposition or article or method, but does not exclude the presence ofother compounds, materials, particles, method steps, even if the othersuch compounds, material, particles, method steps have the same functionas what is named.

It is also to be understood that the mention of one or more method stepsdoes not preclude the presence of additional method steps or interveningmethod steps between those steps expressly identified. Similarly, it isalso to be understood that the mention of one or more components in acomposition does not preclude the presence of additional components thanthose expressly identified.

The materials described as making up the various elements of theinvention are intended to be illustrative and not restrictive. Manysuitable materials that would perform the same or a similar function asthe materials described herein are intended to be embraced within thescope of the invention. Such other materials not described herein caninclude, but are not limited to, for example, materials that aredeveloped after the time of the development of the invention.

The preferred embodiments, discussions and accompanying figures disclosevarious construction materials, their unique arrangement and methodrelating to the manufacture of the DPS sport ball.

For the purpose of demonstration and simplicity, a six panel soccer ballis depicted to show the unique and novel specifications, materials,techniques, and automated manufacturing processes of the presentinvention, but those of skill in the art will understand that similarspecifications and technologies can be applied to various other types ofinflatable sport balls having different purposes and configurations. Forexample, the present invention can comprise an inflatable ball havingvarious number of panels-including 10, 12, 14, 20, and 32 panels—andinclude a variety of ball types, for example, a soccer ball, football,handball, volleyball, futsal ball, and others.

FIG. 1 illustrates a cross-sectional view of a panel P having anexemplary layered system forming the present invention, showing amulti-layered structure having an outer casing that forms an exteriorportion of the sport ball and a plurality of lining layers.

In an exemplary embodiment, outer casing 101 comprises an exclusivelydeveloped, environment friendly casing material, namely environmentfriendly polyurethane (EPU) that has excellent abrasion characteristics,feel and a soft touch.

In addition to the environment friendly exclusive feature of outercasing 101, the present EPU is unique due to its extra soft feel havingfullness and accuracy in control due in part from porous foaming. EPU isalso excellent in hydrolysis and abrasion resistance, so it providesexcellent durability to the ball.

Outer casing 101 can be of materials other than EPU, for example, normalPU, water-borne PU dispersion (WPU), PU micro-fiber, PU high solid, andthermoplastic polyurethane (TPU).

In exemplary embodiments, the outer casing has a thickness within arange of 0.9 mm-1.5 mm.

The present invention further comprises a plurality of lining layers103, 105, and 107, each preferably bonded to adjacent layers via bondingmaterial, for example, 102, 104 and 106.

In an exemplary embodiment, outer casing 101 is attached to a firstlining layer 103 of a plurality of lining layers using a water-basednatural adhesive 102. First lining layer 103 can comprise a woven ornon-woven fabric 103 having a thickness in a range of, for example, 0.5mm-1.5 mm. First lining layer 103 can comprise other types of material,including other forms of compatible fabric.

In an exemplary embodiment, first lining layer 103 is attached to asecond lining layer 105 of the plurality of lining layers using a layerof water-based natural adhesive 104. Second lining layer 105 cancomprise a TPE foam that has excellent heat, water and weatherresistance qualities.

TPE foam is resistant to slip, shock absorption, and has a soft texturethat results in an extra soft touch, flexibility and free flowing of theball in the field. Second lining layer 105 can have a thickness in arange of, for example, 2.00 mm-4.00 mm. Second lining layer 105 cancomprise other types of material, including other forms of compatiblefoam.

In an exemplary embodiment, second lining layer 105 is attached to athird lining layer 107 of the plurality of lining layers using awater-based natural adhesive layer 106. Third lining layer 107 cancomprise a fabric having a surface density in a range of, for example,100 gm/m²-150 gm/m². Lining layer 107 can comprise, for example, 100%polyester, polyester viscose or polyester cotton.

In an exemplary embodiment, woven or non-woven fabric 103 is laminatedto the outer casing 101 by means of a water-based natural adhesive 102using auto machines, layer 103 then bonded to layer 105 by passing themthrough a special laminating or auto-gluing machine that smears a layerof water-based natural adhesive 104. Afterwards, the laminated sheetcomprising multiple layers is passed through a corona machine thatensures even stronger bonding. After corona treatment, the bonded sheetis laminated with another lining layer 107 by means of water-basednatural adhesive layer 106.

FIG. 2 illustrates a cross-sectional view of a panel P of the presentinvention having additional lining layers over the panel of FIG. 1. InFIG. 2, two additional layers 202 and 204 are shown, bonded to adjacentlayers via bonding material 201 and 203.

In an exemplary embodiment, layer 202 comprises TPE foam, and layer 204is in the form of a round patch 204.

FIG. 3 illustrates an exemplary sheet 300 sized to provide optimalpanels with minimal waste. The compatible sizing of a laminated sheet isdone using a specially developed sheet sizing machine equipped withlaser guided presses. Preferably, the size of the sheet is adjustedwithin a range of 100 cm×70 cm. Alternatively, the size of a sheet isadjustable to other ranges, such as 100 cm×69 cm, 97.59 cm×70.0 cm, etc.as per specific requirements.

FIG. 4a illustrates sheet 300 being used to create an average of 24panels P (that have been specifically designed) on a sheet of dimensions100 cm×70 cm, the panels preferably formed in one stroke, using anoptimized auto-printing machine. In an alternative embodiment, forexample, in the case of a size 5 ball having a 32 panel configuration,104 (large) hexagonal panels and 98 (small) pentagonal panels areprinted in one stroke on sheet 300.

In other embodiments, other numbers and shapes of panels can be printedin a single stroke onto a sheet 300 such as printing an average 42circular panels as illustrated in FIG. 4b , printing an average 42hexagonal panels as illustrated in FIG. 4c , printing an average 104pentagonal panels as illustrated in FIG. 4d , and printing an average 36pentagonal panels as illustrated in FIG. 4e , among others.

Similarly, for size 4 or size 3 balls, a variety of numbers andconfigurations of panels P can be printed in a single stroke, as per thespecific requirement.

FIG. 5 illustrates debossing an average 24 panels P on a sheet 300 inone stroke, using a specifically optimized machine after printing. Basedon the specific requirements, the printed sheet 300 can move to the nextmanufacturing process without debossing.

FIG. 6a illustrates a sheet 300 with the panels P cut therefrom. Here,an average 24 specifically designed panels can be cut in one strokeusing a specifically developed cutting machine.

In alternative embodiments, other shapes can be cut out in a singlestroke from a sheet, such as average 98 hexagonal panels cut out in asingle stroke as illustrated in FIG. 6b . Other examples, include, inthe case of a size 5 ball, 104 (large) hexagonal panels and 98 (small)pentagonal panels cut out in one stroke.

FIG. 7a illustrates an exemplary embodiment of a single panel P from anouter view having a debossing effect.

FIG. 7b illustrates the panel P of FIG. 7a from an inner view, showing aconfiguration of the plurality of layers, and relative sizes and shapesof such layers.

FIG. 7c illustrates a variety of different shapes of panels P from anouter view. FIG. 7d illustrates the panels P of FIG. 7c from an innerview.

FIG. 8 illustrates an exemplary embodiment of a die-punching machine 400using a specifically designed computer numeric controlled (CNC) punchingpress. The machine 400 used is highly optimized to work efficiently andaccurately on the multi-layered panels and punch holes on all sides ofthe multiple panels simultaneously in a single stroke before they arestitched together to form a ball.

FIG. 9 illustrates an automated stitching machine 500 with uniquefeatures including an air pressure system to control, press and stitchmost or all of the panels, and even then, perhaps only a portion of thestitching to leave portion(s) of stitching to be manually stitched.However, other compatible stitching machines can be employed and used tostitch the panels together.

FIG. 10 illustrates in an exemplary embodiment an overall appearance ofa plurality of panels P having been machine-stitched to form ball 600.The TPE foam layer 202 has been bonded by means of water-based naturaladhesive 201. Additionally, other compatible foam may also be laminated.

Additionally, round or any other compatible shaped patches of TPE foam204 or other compatible foam can be bonded using water-based naturaladhesive 203.

Accordingly, a TPE foam round patch can have a thickness within a rangeof 1.5 mm-3.00 mm to create a variety of pressure, preferably dualpressure, thus forming greater seams on the ball.

FIG. 11a illustrates an exemplary bladder 700 wrapped with a specialfabric 702.

FIG. 11b illustrates an exemplary bladder 700 that is thread wound viathread 704.

In exemplary embodiments, the bladder used is a specific compatiblerubber bladder, additionally wrapped with a special compatible fabric(FIG. 11a ) or thread wound (FIG. 11b ) to retain air, maintainrobustness and spherecity of the ball.

Alternatively, the bladder can be formed of other materials, such asnatural latex, butyl, carbon latex, and PU.

During the manufacturing process, the partially machine-stitched sportball is then reversed such that it already contains a suitable bladder.

FIG. 12a illustrates an exemplary sport ball 600 with the bladder 700exposed before manual stitching. The remaining portion of the panels isthen manually stitched, to close the ball.

FIG. 12b illustrates an overall appearance of the present DPS sport ball600 after manual stitching is complete.

The seams S are then protected with a special adhesive application,illustrated in FIG. 13

In an exemplary embodiment, the inflated sport ball is passed through amolding process to attain the round shape of the ball.

The inflated sport ball is then kept for 48 hours to ensure standard airretention and also to identify/rule out risk of slow leakage.Thereafter, the ball is cleaned, washed, dried, deflated and passedthrough a metal detector machine, wherein the sensitivity of thedetector machine to metals is up to 1.00 mm so even small imperfectionsare found.

Resultantly, due to the unique and novel construction materials, theirnovel and specific arrangement, innovative techniques, and highlyautomated manufacturing processes, the present

DPS sport ball has a top quality, durability, playability,controllability and an excellent flight characteristics.

The present DPS sport ball manufactured by this process qualifies in allthe international standards of a match/professional ball at a verycompetitive price.

Numerous characteristics and advantages have been set forth in theforegoing description, together with details of structure and function.While the invention has been disclosed in several forms, it will beapparent to those skilled in the art that many modifications, additions,and deletions, especially in matters of shape, size, and arrangement ofparts, can be made therein without departing from the spirit and scopeof the invention and its equivalents as set forth in the followingclaims. Therefore, other modifications or embodiments as may besuggested by the teachings herein are particularly reserved as they fallwithin the breadth and scope of the claims here appended.

1. A dual pressure system (DPS) sport ball comprising: an outer casingforming an exterior surface of the ball; an inner bladder; and amultiple lining system, the multiple lining system located between theouter casing and the inner bladder.
 2. The DPS sport ball of claim 1,wherein the outer casing is selected from the group consisting ofpolyurethane (PU), environment friendly PU (EPU), water-borne PU (WPU),PU micro-fiber, PU high solid and thermoplastic PU (TPU).
 3. The DPSsport ball of claim 1, wherein the outer casing comprises EPU.
 4. TheDPS sport ball of claim 1, wherein the multiple lining system comprisesat least three lining layers.
 5. The DPS sport ball of claim 1, whereinthe multiple lining system comprises five lining layers.
 6. The DPSsport ball of claim 1, wherein the inner bladder is a speciallydeveloped rubber bladder.
 7. The DPS sport ball of claim 1, wherein themultiple lining system comprises five lining layers; wherein the outercasing comprises a material selected from the group consisting of PU,EPU, WPU, PU micro-fiber, PU high solid and TPU; wherein each of thefive lining layers comprise a material selected from the groupconsisting of fabric and foam; wherein each of the five lining layers isbonded to an adjacent lining layer with a bonding material; and whereinthe multiple lining system is bonded to the outer casing to form apanel.
 8. The DPS sport ball of claim 5, wherein each lining layercomprises a material selected from the group consisting of fabric andfoam; and wherein each lining layer is bonded to an adjacent lininglayer with a bonding material.
 9. The DPS sport ball of claim 6, whereinthe bladder is wrapped with a fabric
 10. The DPS sport ball of claim 6,wherein the bladder is wound with a thread.
 11. The DPS sport ball ofclaim 7, wherein the bonding material between each lining layer isselected from the group consisting of a natural adhesive and a syntheticadhesive.
 12. The DPS sport ball of claim 7, wherein the bondingmaterial between each lining layer comprises a water-based naturaladhesive.
 13. The DPS sport ball of claim 7, wherein a first lininglayer of the multiple lining system comprises a material selected fromthe group consisting of woven fabric and non-woven fabric, the firstlining layer bonded to the outer casing; wherein a second lining layercomprises a foam material, the second lining layer bonded to the firstlining layer; wherein a third lining layer comprises a material selectedfrom the group consisting of polyester viscose, polyester cotton, and100% polyester fabric, the third lining layer bonded to the secondlining layer; wherein a fourth lining layer comprises a foam material,the fourth lining layer bonded to the third lining layer; and wherein afifth lining layer comprises a foam material, the fifth lining layerbonded to the fourth lining layer, the fifth lining layer being inproximity to the inner bladder.
 14. The DPS sport ball of claim 7,wherein the surface of the panels is debossed.
 15. The DPS sport ball ofclaim 7, wherein the surface of a panel is debossed with two parallellines.
 16. The DPS sport ball of claim 13, wherein the foam material ofthe second, fourth and fifth lining layer comprises thermoplasticelastomer (TPE) foam.
 17. The DPS sport ball of claim 13, wherein eachof the outer casing, first, second and third lining layers is ofapproximately the same surface area; and wherein the fourth and fifthlining layers of each panel has a smaller surface area dimension thanthat of the outer casing, first, second and third lining layers.
 18. TheDPS sport ball of claim 17, wherein the fifth lining layer has a smallersurface area dimension than that of the fourth lining layer.
 19. The DPSsport ball of claim 18, wherein the fifth lining layer are in the formof a patch/es.
 20. The DPS sport ball of claim 19, wherein each patchhas a surface area in the range of 9.62 cm²-19.63 cm².
 21. The DPS sportball of claim 19, wherein each patch has at least one aperturetherethrough, each aperture having a surface area in the range of 0.38cm²-3.14 cm².
 22. The DPS sport ball of claim 19, wherein each patch hasat least one aperture therethrough; wherein each patch is round havingdiameter in the range of 3.5 cm-5 cm; and wherein each aperture is roundhaving diameter in the range of 0.7 cm-1 cm.
 23. A dual pressure system(DPS) sport ball comprising: an outer casing forming an exterior surfaceof the ball; an inner bladder; and a multiple lining system having fivelining layers, the multiple lining system located between the outercasing and the inner bladder, an outer surface of the multiple liningsystem bonded to the outer casing, and an inner surface of the liningsystem surrounds the inner bladder; wherein the outer casing is selectedfrom the group consisting of PU, environment friendly PU (EPU), WPU, PUmicro-fiber, PU high solid and TPU; wherein each of the five lininglayers comprise a material selected from the group consisting of fabricand foam; wherein each of the five lining layers is bonded to anadjacent lining layer with a bonding material; and wherein the wateruptake by the ball is less than 0.4%.
 24. A method of manufacturing thedual pressure system (DPS) sport ball of claim 1 comprising: forming asheet of the multiple lining layers; laminating the outer casing sheetto the multiple lining layers; sizing the sheet; printing panels;cutting the panels; die-punching the panels; machine stitching thepanels; incorporating the inner bladder; manually stitching of theremaining portion of the panels to close the ball; and protecting seamsof the outer casing.
 25. The method of manufacturing the DPS sport ballof claim 24, wherein the multiple lining layers are laminated to theouter casing by means of adhesive to form a sheet; and wherein thelaminated sheet is sized by utilizing specific laser guided presses. 26.The method of manufacturing the DPS sport ball of claim 24 furthercomprising the printing of multiple panels on a sheet by a highlyoptimized printing machine; wherein multiple panels of specific shapeand size are printed in a single stroke.
 27. The method of manufacturingthe DPS sport ball of claim 24 further comprising debossing on theprinted panels by a debossing machine.
 28. The method of manufacturingthe DPS sport ball of claim 24 further comprising the cutting ofmultiple printed panels in a single stroke by using a cutting machine.29. The method of manufacturing the DPS sport ball of claim 24 furthercomprising die-punching of the panels by computer numeric controlled(CNC) punching presses to form holes on both sides of the panels forstitching in one stroke.
 30. The method of manufacturing the DPS sportball of claim 24 further comprising the stitching of the panels bystitching machine, equipped with a special air pressure system to pressand control the panels.
 31. The method of manufacturing the DPS sportball of claim 24 further comprising the bonding of additional fourth andfifth layer to each of the panels of the ball with a water basedadhesive.
 32. The method of manufacturing the DPS sport ball of claim 24further comprising the manual stitching of remaining portion of panels,to close the ball.
 33. The method of manufacturing the DPS sport ball ofclaim 24 further comprising protecting seams of adjacent panels; whereinthe special adhesive is applied manually or by auto-machine.
 34. Themethod of manufacturing the DPS sport ball of claim 24, wherein the ballis optionally passed through a molding process, to retain round shape ofthe ball.
 35. The method of manufacturing the DPS sport ball of claim26, wherein the shape of the printed panel is selected from the groupconsisting of octagonal, hexagonal, pentagonal, and circular.
 36. Themethod of manufacturing the DPS sport ball of claim 31, wherein the ballis reversed manually and the inner bladder is incorporated.